I recently removed and refitted my brother's diesel pump so he can have it reconned.

If I was to do it again these are the key notes I would recommend.

- Clean the engine before starting the job.
- disconnect the battery before you start as you have an unfused 12v wire to the starter close by - bracelets burn badly - I learned the hard way with my sister's mini a few years back.
- the intercooler comes out as a whole with the 2x top bolts and 2 radiator located bolts (don't remove all the other ones holding the intercooler to the bracket)
- remember to mark the throttle cable.
- a 12 ring spanner ratchet is a lifesaver for the bolt located behind the aircon belt tensioner pulley - otherwise spray the bracket with penetrating oil and remove the idler for access
- triple mark and triple check the timing - this isn't something that you want to get wrong as it involves removing the whole pump to reset it - I luckily got it right first time round by marking the teeth on the pumps gear and the power steering pump housing surface.
- redo all the coolant pipes and fuel pipes around it while you have access.
- check that the injector pipes are securely tightened at the pump before fitting as they are a PITA to tighten once the pump is in. Alternatively you can fit the pipes separately one by one, but I felt it risked getting dirt in them.
- change the fuel filter at the same time while you have easy access - the water sensor's wiring at the bottom of the filter is EXTREMELY brittle!
- prefill the diesel filter with diesel to save on hand priming.
- make sure you have a fully charged battery when trying to start - if you missed a few things you might have to try a few times.
- if you have small hands with great dexterity it isn't too bad to just remove the bolt at the bottom on the bracket instead of removing the 2x bolts that bolt the bracket onto the block. ( But get it to thread in before you bolt the pump tight ) - in hindsight, I will in future, rather try the 2x bolts against the block.

Other than that, if you work systematically and organised and put all the bolts back in the places where you removed them from it is a fairly easy job to do. For me the worst part was the bolt behind the A/C idler pulley ( 40 minutes to get it back in )

It's really nice to see how these engines work, the way you fixed it really gets your hand really dirty. This is just the best thing about the assembly architecture of any vehicle once you get it busted you take it all apart and put them back together.